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Old 11-10-2015, 01:37 AM   #1
KornShaDoW097
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Member#: 313618
Join Date: Mar 2012
Location: South San Diego
Vehicle:
2004 WRX

Default Hfs-3 connectors

I noticed my brown wire on the ECU plug connector is somehow melted...it kept triggering safe mode.

What type of connector is used? It looks like a 10 pin RJ45 ethernet male connector. But pin 1 and 10 are not used. So I bought a 8 pin RJ 45 but the wire guides seem smaller than the wire diameter.

Anyone know what connector this is? Is a 10 pin RJ45 larger diameter wire btw?

Thanks
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Old 11-10-2015, 12:27 PM   #2
Aquamist
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Location: Sussex, England
Vehicle:
2004 Citroen Picasso
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How do you come to this conclusion? I have never seen this before.
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Old 11-10-2015, 02:36 PM   #3
KornShaDoW097
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I kept blowing fuses on the line leading to the relay. I found a short and fixed it. Which was making the pump not come on.

My battery was low so i hooked up a second battery to help it out. The system ran fine during testing but on the second run the fav and pump stayed ON, even after the SYS jumper was disconnected and the amber thresh light stayed on.

I tested every harness to isolate the issue. First trunk, then fav. I figured out how the wiring worked on the Fav and figured out It relays power to the trunk. Which triggers the magnetic coil on the relay.

It was somehow receiving signal and after activation it would not stop. At first i noticed a click of the black coils on the hfs. But after a few resets and disconnecting harnesses depending on if i wanted the coils to trigger or not. I found the only time the amber light (gauge also showed w injection and sometimes both ambers) was if the ecu wire plug was unplugged. Then i saw the brown melted wire on the inside of the rj45 or 10P10C connector. At first it looked like 3 wires were bad but i saw pin 1 and 10 were there for possibly future/different applications. The wire after the connector is fine. So it must have been not making a good contact or arching on the black wire causing an issue after start up.
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Old 11-10-2015, 02:59 PM   #4
KornShaDoW097
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Anyway, The 10pin RJ45, do you know the gauge the wires are? Or the Category? (5,5e,6)

22,23 or 24AWG? Because they dont seem to fit in Cat5e 24AWG connectors.

Do you think dielectric grease would help them slide?

Cat5/5e is 24AWG, Cat6 is 23AWG...

If nothing else I'll use Cat6 connectors next.

Jon
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Old 11-12-2015, 08:00 PM   #5
KornShaDoW097
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Booklet says RJ48 24AWG. However there is a manufacturer defect. I dont think the wire was burned. I think it was made this way on purpose.

The ECU plug brown wire, its insulation is out of spec. It is NOT 24AWG as all other wires are. This causes a Rj45/48 with 24AWG spec even a CAT6 23AWG capacity connector NOT to fit. All other wires fit fine (black is a bit tight too but still capable of fitting).

So I believe when being built by Aquamist the builder had no choice but to strip the insulation completely off on the connector. (I have pics) in order to not have to re order the correct spec. This could be a reason why i and many others receive interference and have the failsafe kick in at random and cause shorts.

The wire is completely exposed, can arc on neighboring wires and cause interference.
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Old 11-12-2015, 08:02 PM   #6
KornShaDoW097
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Even mess with the Boost Controller and potentially damage it.
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Old 11-13-2015, 08:22 PM   #7
KornShaDoW097
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I replaced the connector with a EZRJ45 connector (shielded) CAT 6, 8P8C.

The brown wire requires substantial trimming of insulation but you can twist the wire and add dielectric to keep it from contacting other wires. To slip the rest in just add dielectric grease to help everything else fit.

Done.
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Old 11-14-2015, 03:48 AM   #8
Aquamist
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2004 Citroen Picasso
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I advise you to seek help to have the system installed, so far you are getting nowhere. From previous communications, you have had the system for 1.5 years and still struggling to make it work. Blaming the system every step of the way.

The term "little knowledge is dangerous" describes you perfectly.
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Old 02-02-2016, 06:46 PM   #9
KornShaDoW097
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Location: South San Diego
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2004 WRX

Default Hfs-3 connectors

Wrong. I had it working day 1, but these low quality connectors and relays keep the system acting strange.

You guys use the RJ45 or 8P8C yet the wires in question are the incorrect insulation thickness. Brown being most obvious since they stripped the insulation.5" from factory. I bet if others look at the 8pin harness on ECU connector they will have the same stripped wire I mentioned.

Plus the relay broke apart at the fuse terminal like a year in . So those two factors have nothing to do with me.

And those are the only problems. I fixed them And the system works fine again.

Well that and the plastic housing for the FAV plug literally cracked and fell apart and caused a short from vibration.

All of which I found and repaired no thanks to your condescending replies.
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